Disc Brake Sensor Harness Routing With Retraction Spring Attachment
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Solution Overview
Problem
Existing disc brake assemblies face challenges in securely attaching and routing wire harnesses to prevent damage during operation, particularly due to the risk of pinching between brake pad assemblies and the rotor, which can lead to malfunction and reduced reliability.
Innovation Solution
The disc brake assembly incorporates a wire harness that is attached to the brake pad retraction springs using various attachment features, such as coil springs and anti-rotation mechanisms, to ensure secure routing and prevent pinching, thereby enhancing the durability and reliability of the sensor assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire harness is routed through the brake assembly without attachment features, then the device complexity is reduced, but the wire harness is at risk of pinching between brake pad assemblies and the rotor, leading to damage and malfunction
Solution Approach 1:
The patent introduces attachment features (clips, ties, or engagement structures on the retraction spring) as intermediary elements between the wire harness and the brake assembly components. These intermediaries secure the wire harness to the retraction spring or brake pad assembly, preventing direct contact and pinching between the wire harness and the rotor, thereby protecting the wire harness without requiring fundamental redesign of the brake assembly
Solution Approach 2:
The wire harness is attached to the retraction spring or brake pad assembly during the assembly process before the brake system is put into operation. This preliminary attachment ensures that the wire harness is properly positioned and secured before any braking operations occur, preventing pinching and damage from the outset while maintaining a relatively simple overall structure
2Reliability
If the wire harness is securely attached to the retraction spring with multiple attachment features, then the wire harness is protected from pinching and damage, but the manufacturing and assembly process becomes more complex
Solution Approach 1:
The retraction spring is designed with integrated engagement structures (such as built-in clips or attachment points) that automatically secure the wire harness during normal assembly operations. This self-service approach allows the wire harness to be attached without requiring separate, complex attachment mechanisms or additional manual steps, thereby protecting the wire harness while maintaining ease of manufacture and assembly
Solution Approach 2:
The attachment features are merged with the retraction spring structure itself, combining the functions of the retraction spring and the wire harness attachment mechanism into a single integrated component. This merging eliminates the need for separate attachment devices and simplifies the manufacturing and assembly processes while ensuring reliable protection of the wire harness
3Ease of operation
If the wire harness is allowed to move freely within the brake assembly, then the ease of installation is improved, but the wire harness is susceptible to pinching and damage during brake operation
Solution Approach 1:
The attachment features act as intermediaries that guide and secure the wire harness in a predetermined safe path within the brake assembly. During installation, the wire harness can be easily attached to the retraction spring or brake pad assembly, and during operation, these same attachment features prevent the wire harness from moving into hazardous zones where pinching between the brake pads and rotor could occur, thus protecting against harmful factors while maintaining installation ease
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively secures the wire harness, reducing the risk of damage and ensuring reliable operation by allowing limited movement while preventing pinching between the brake pad assemblies and the rotor, thus enhancing the overall performance and longevity of the disc brake system.
Implementation Method 1
a first brake pad retraction spring (30) that extends between the first and second brake pad assemblies (24, 24) and that biases the first and second brake pad assemblies (24, 24) away from each other
Implementation Method 2
The attachment feature may be a coil spring that defines a coil spring passage through which the first brake pad retraction spring and the wire harness extend
Data Source
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AI summary
A disc brake assembly that includes at least one brake pad retraction spring and a sensor assembly. The brake pad retraction spring extends between a pair of brake pad assemblies. The sensor assembly includes at least one sensor and a wire harness. The sensor is disposed on a brake pad assembly. The wire harness is attached to the brake pad retraction spring.